Method of packaging an innerspring mattress

ABSTRACT

The present invention relates to an improved method of packaging a innerspring mattress. Various embodiments include placing the mattress in a bag, compressing the mattress and bag, sealing the bag, then rolling the mattress and bag into a cylinder shaped roll. Other embodiments include securing the rolled mattress and bag with tape, then placing into a second bag for shipment and storage. An additional embodiment discloses a method of packaging a foam encased innerspring mattress.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method of packaging a innerspring mattress.

2. Reference to Related Art

Mattresses, including innerspring mattresses, are known in the industry. For instance in Wells (U.S. Pat. No. 5,509,642) describes an innerspring structure for a mattress comprising a plurality of outer coils extending generally parallel with each other to collectively form top and bottom face surfaces of the innerspring structure. One or more of the outer coils has an inner coil of preferably similar shape wound within and generally coaxially with the respective outer coil. Helical lacing wire wraps adjacent end turns of the inner and outer coaxially aligned coils together to form reinforced coil units in an area of the innerspring structure to increase the firmness of an area of the mattress utilizing the invention.

Richmond (U.S. Pat. No. 6,149,143) describes an innerspring structure for a mattress comprising a row of outer coils formed from a continuous piece of wire with the coils interconnected with interconnection segments and a row of inner coils similarly formed. The interconnection segments of the coils form coil heads for pairs of adjacent coils and each head includes a first linear portion disposed generally parallel to the row. The row of inner coils is positioned together and generally coaxially with the row of outer coils for forming reinforced coil units. A helical lacing structure winds around portions of the inner and outer coils to couple the coils together into reinforced coil units and the first linear portions of the coils are configured for being captured with at least approximately three loops of the helical lacing structure for forming a row of reinforced coil units.

However, problems with these, and the other existing innerspring mattresses known in the art, include high transportation and storage costs, given their bulky and awkward shape. As such, retail mattress stores are often limited in the number of mattresses they store on site. This, in turn, often lead to delays and inefficiencies in delivering the mattresses to customers.

It is therefore an object of the present invention to remedy these problems by reducing the costs associated with transporting and storing innerspring mattresses.

SUMMARY OF THE INVENTION

The present invention relates to a method of packaging an innerspring mattress. The packaging method described herein includes placing an uncompressed innerspring mattress into a first enclosure means, such as a plastic or cloth bag. The bag is preferably open on one or more sides to allow the mattress to be easily placed into it. The mattress is then compressed, preferably by a mechanical press machine. The compression could also be accomplished by creating a vacuum within the first enclosure means, or by through other means. The bag is then closed and sealed, thereby maintaining the mattress in its state of reduced thickness. The mattress and bag are then rolled into a cylinder shape and preferably taped so as to keep the mattress from unrolling. Alternatively, the mattress and first enclosure means can be folded before rolling. In an embodiment, the rolled mattress can placed into a second enclosure means, such as a second bag. This second bag could be made from a variety of materials, including, but not limited to, polyurethane (PE), plastic, or cloth or other fabric.

This method allows the rolling of the mattress to be carried out by hand. In its thin, compressed state, the mattress and first bag can be folded and rolled without the use of mechanical assistance. As such, costly equipment investments can be reduced. Alternatively, the folding and/or rolling could be accomplished with mechanical assistance.

Generally, mattresses can be constructed using a variety of support systems, such as air, water, foam, or springs. The term “innerspring mattress” is used herein to describe any bedding apparatus that generally encloses springs in a compartment. The compartment that encloses the springs can be made from a variety of materials, including but not limited to foam, fabric, fiber, felt, or plastic. However, the material that encloses the springs can be made from any suitable material. The term “mattress” includes not only the typical finished consumer bedding product that typically contains fabric padding surrounding the apparatus. As used herein, a “mattress” may also include an apparatus that does not include any cover around the enclosed springs. Such a mattress is often referred to as a mattress “core”. A mattress “core” could be packaged and/or sold separately from a mattress cover, wherein the cover can be placed on or around the core. Mattress covers could vary in attributes such as firmness, height, etc. In any event, the term “mattress” as used herein may include a mattress “core”, as well as a mattress that includes a covering.

The term “foam” can include materials such as latex foam, viscoelastic foam and other polyurethane-type foams. The springs contained in mattresses are typically made from steel and usually provides at least a portion of the structure of the mattress. The term “spring” as used herein can include a variety of structures that provide or allow movement by elastic force. This includes the typical spiral shaped springs, but can also include other shapes or mechanisms, including but not limited to Z shaped springs, and/or spacers or other devices that provide structure and/or elastic force to the mattress.

The method described herein is ideally suited to foam encased innerspring mattresses using pocket springs, due to the increased flexibility of pocket springs. However, foam encasement and/or pocket springs are not requirements or limitations of the invention. Typically, wire support that encircles the perimeter of the mattress is used to provide stability to the mattress. However in this invention, it is not recommended that such a configuration be used, since such an embodiment would create a greater likelihood of damaging the mattress during the packaging process. Preferably, pocket springs will be used that are individually wrapped with adhesive-bonded fabric. The adhesive-bonded fabric pockets are not only used for wrapping the spring, but also for isolating the springs from the foam material that encases them.

However, this method may also be utilized on other types of spring mattresses, including, but not limited to, Bonnel type springs that have knotted end turns on the springs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a partially sectionalized group of three attached pocket coils.

FIG. 2 is a perspective view of attached pocket coils.

FIG. 3 is a perspective view of a mattress according to the invention.

FIG. 4 is a perspective view of a mattress inside of a packaging bag.

FIG. 5 is a perspective view of a mattress inside of a packaging bag shown in its compressed state.

FIG. 6 is a perspective view of a folded mattress and packaging bag.

FIG. 7 is a perspective view of a folded mattress and packaging bag after it has been compressed and rolled into a cylinder shaped roll and taped.

FIG. 8 is a perspective view of the rolled mattress and packaging bag, placed in a second bag.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a mattress according to an embodiment of the invention. It shows an uncompressed innerspring mattress. In this particular drawing, a block of polyurethane foam 18 is shown that encases inner spring coils 16 embedded in the foam. The springs 10 shown here are pocket coils 16 that are individually wrapped. However, the invention could also utilize a variety of other spring arrangements, including Bonell springs, which are attached to each other.

FIG. 2 shows the innerspring mattress 18 after it has been placed into a first enclosure means 20. The first enclosure means 20, and in this instance a bag 20, can be made from a variety of different materials, including but not limited to plastic, vinyl, PE, fabric, cloth, etc. Preferably, the first enclosure means 20 will comprise a sealable opening at one end. This will allow for the convenient placement of the mattress into the bag 20, as well as the closing/sealing of the end of the mattress bag after the mattress and bag 20 have been compressed. To minimize the amount of material used for the mattress bag 20, the shape of the bag will preferably be similar to the mattress. However, this is not a requirement of the invention.

FIG. 3 shows the innerspring mattress 18 and first enclosure means 20, in this instance a bag 20, after they have been compressed. The means of compression is preferably a press machine that presses the mattress and bag in a generally flat and even manner. The packaging process will be optimized if the first enclosure means 20, such as the bag shown here, is closed/sealed while the press machine holds the mattress in a compressed state. This will keep the mattress from expanding before the bag 20 can be sealed. Other methods of compression may include creating a vacuum that causes the mattress and first enclosure means to compress Once the bag is sealed, the mattress should stay compressed, and thus be amenable to folding and/or rolling.

FIG. 4 shows an embodiment where the mattress is in its first enclosure means 20, compressed, and folded once before rolling. This embodiment may have advantages from the other embodiments in that less rolling needs to be done to put the mattress into a cylinder shaped roll. In a preferred embodiment, the rolling begins on the shortest end of mattress to reduce the height of the mattress after rolling. However, this is not a requirement of the invention.

FIG. 5 shows the mattress and first enclosure means after they have been rolled. FIG. 5 also shows the mattress and first enclosure means rolled and secured with tape 22. This embodiment utilizes two pieces of tape 22 to secure the rolled mattress and bag, but other taping configurations may be equally effective. An important purpose of taping the mattress and bag 20 after they've been rolled is to maintain their shape, and keep them from unrolling. Since the first enclosure means 20 is covering the entire mattress, the tape will only contact the bag 20, and not the mattress. Therefore, when the mattress is unpackaged, the tape 22 can be removed without damaging the mattress.

The amount and/or configuration of the tape 22 is unimportant, as long as the it holds the mattress and first enclosure means 20 such that they do not unroll. Single-sided adhesive tape will suffice to join the adjoining materials, in this case the adjoining exterior portions of the first enclosure means 20. Although adhesive tape is the preferred means of holding the rolled mattress 18 and first enclosure means 20 in a rolled state, additional means of accomplishing this are also anticipated by this invention. These alternate means include string, Velcro, enclosure into a second bag, etc. A preferred embodiment for this invention will utilize a temporary securing means, such as adhesive tape 22, to keep the rolled mattress 18 and first enclosure means 20 in a rolled state. The rolled and taped mattress and first enclosure means 20 may then be placed into a second enclosure means 24, such as a cloth or plastic bag, with a reduced chance of unrolling before placement, and with less pressure placed on the second enclosure means 24.

An advantage of this invention is to allow the mattress to be more easily handled and stored.

Applicant asserts that the mattress in its compressed and rolled state has advantages in both handling and storage.

FIG. 6 shows the mattress and first enclosure means after they have been folded and rolled. An advantage of this embodiment, where the mattress is folded before it is rolled, is that less rolling needs to be performed to place the mattress into a rolled, cylindrical shape. As with FIG. 5, this drawing also shows the mattress and bag secured in the rolled state with tape 22. This embodiment utilizes two pieces of tape 22 to secure the rolled mattress and bag, but other taping configurations may be equally effective. An important purpose of taping the mattress and bag 20 after they've been rolled is to maintain their shape, and keep them from unrolling. Since the bag 20 is covering the entire mattress, the tape will only contact the first enclosure means 20, and not the mattress. Therefore, when the mattress is unpackaged, the tape 22 can be removed without damaging the mattress.

FIG. 7 In additional embodiments, the folded and/or rolled mattress can also be taped or otherwise restrained into the cylinder shaped roll, and placed into a second enclosure means 24, such as another bag. This second enclosure means 24 may be made from a variety of different materials, including but not limited to fabric, cloth, plastic, PE, etc. FIG. 7 shows a perspective view of an embodiment of the invention wherein a second enclosure means 24 surrounds the rolled mattress and first enclosure means. The second enclosure means 24 may utilize a variety of methods of closure, including, but not limited to drawstrings, Velcro, button(s), snaps, or clips. 

1. A method for packaging a rectangular shaped, innerspring mattress, comprising the following steps: a. Placing an uncompressed innerspring mattress into a first enclosure means, wherein the first enclosure means is open on at least one portion; b. Compressing the mattress and first enclosure means; c. Sealing the open portion(s) of the first enclosure means; d. Rolling the mattress and first enclosure means into a cylinder shaped roll.
 2. A method for packaging a rectangular shaped, innerspring mattress, comprising the following steps: a. Placing an uncompressed innerspring mattress into a first enclosure means, wherein the first enclosure means is open on at least one portion; b. Compressing the mattress and first enclosure means; c. Sealing the open portion(s) of the first enclosure means; d. Folding the mattress and first enclosure means; e. Rolling the folded mattress and first enclosure means into a cylinder shaped roll.
 3. The method of claim 1 or 2, further comprising taping the cylinder shaped roll such that the cylinder shape is retained.
 4. The method of claim 1 or 2, further comprising enclosing the cylinder shaped roll into a second enclosure means.
 5. The method of claim 1 or 2, wherein the rolling of the mattress and first enclosure means into a cylinder shaped roll is done without mechanical assistance.
 6. The method of claim 1 or 2, wherein the rolling of the mattress and first enclosure means into a cylinder shaped roll with mechanical assistance.
 7. The method of claim 1 or 2, wherein the compression of the mattress and first enclosure means is utilizes a press machine.
 8. The method of claim 1 or 2, wherein the compression of the mattress and first enclosure means is accomplished by creating a vacuum within the first enclosure means.
 9. The method of claims 1 or 4, wherein the first enclosure means comprises a bag.
 10. The method of claims 1 or 4, wherein the second enclosure means comprises a bag.
 11. The method of claims 1 or 4, wherein the first enclosure means comprises a plastic bag.
 12. The method of claims 1 or 4, wherein the second enclosure means comprises a plastic bag.
 13. The method of claims 1 or 4, wherein the first enclosure means comprises a cloth bag.
 14. The method of claims 1 or 4, wherein the second enclosure means comprises a cloth bag.
 15. The method of claims 1 or 4, wherein the first enclosure means comprise a polyethylene bag.
 16. The method of claims 1 or 4, wherein the second enclosure means comprise a polyethylene bag.
 17. The method of claims 1 or 2, wherein the innerspring mattress comprises pocket springs.
 18. The method of claims 1 or 2, wherein the innerspring mattress comprises Bonnet springs.
 19. The method of claims 1 or 2, wherein the springs are encased in foam.
 20. The method of claims 1 or 2, wherein the springs are encased in at least one fabric material.
 21. The method of claims 1 or 2, wherein the springs are encased in at least one fiber material.
 22. The method of claims 1 or 2, wherein the springs are encased in at least one felt material.
 23. The method of claims 1 or 2, wherein the springs are encased in at a plastic material.
 24. The method of claim 1 or 2, wherein the cylinder shaped roll is retained by placing a material around the roll that is resistant to stretching;
 25. The method of claims 1 or 2, wherein the mattress is rolled along the short end of the mattress, such that when the rolling of the mattress is complete, the height of the cylinder shaped roll is approximately the length of the shortest side of the mattress. 